Success Stories / Increased Line Efficiency and More Following Shop Floor Documentation & Training

Increased Line Efficiency and More Following Shop Floor Documentation & Training

$300mn Manufacturer

|

BACKGROUND

A new CEO was hired to lead the turnaround of a multisite food manufacturer. He retained a new operations team and tasked them with building a high-performance operational culture focused on continuous improvement.

At the time, the business was experiencing high employee turnover, long changeover times, late shift start-ups, and low order fulfillment rates.

SERVICES

  • Operational Excellence

ASSESSMENT

The new VP of Ops and Plant Manager observed a lack of training materials for new hires and outdated work processes.

Saphineia developed a strategy to create the critical documents.

We built the documents with the Subject Matter Experts’ input on current best practices.

RESULTS

We produced documentation for:

  • Standard Work Instructions
  • Centerlines
  • One Point Lessons
  • Checklists
  • Labor Playbooks
  • Leader Standard Work

We then trained the front-line leaders, machine operators, and hourly workforce.

As a result:

  • Start-up time decreased by 50%
  • Change-over times declined by 25%
  • Line efficiency increased by 5% in 8 weeks

CLIENT BENEFITS

  • Increased employee morale
  • Improved line efficiency and throughput
  • Improved shift hand off and communication
  • Reduced maintenance and machine operator frustrations

Interested in working with us?